Caseless tier sheet

ABSTRACT

A tier sheet includes a deck having a support surface. A plurality of walls extend downward to define lower recesses for receiving the upper ends of containers therebelow. In one embodiment, the tier sheet is a single thermoformed sheet and includes a plurality of upper recesses formed in the deck, each upper recess defined between an outer wall and a column. In another embodiment, the tier sheet is injection molded.

BACKGROUND

Dairy (e.g. milk) is often sold in 1 gallon plastic containers or jugs. The traditional milk jug has a generally rectangular cross-section body tapering down to a neck portion with a cap. The milk jugs may be shipped to stores in crates, which are then returned and reused.

More recently, “caseless” milk jugs have a generally rectangular (generally square with rounded corners) cross section, including the uppermost portion of the jug, which includes short neck portion protruding up from an upper wall. A raised portion on the upper wall is generally coplanar with the cap on the neck. Corrugated cardboard tier sheets separate layers of the milk jugs.

SUMMARY

Tier sheets disclosed herein provide increased stability for the traditional or “caseless” dairy containers, while providing a more space-efficient, reusable solution. A tier sheet includes a deck having a support surface. A plurality of walls extend downward to define lower recesses for receiving the upper ends of containers therebelow.

In one embodiment, the tier sheet is injection molded. The disclosed example injection molded tier sheet is specifically designed for the caseless dairy containers described above, but could be modified for other types of containers.

In another embodiment, the tier sheet is a single thermoformed sheet and includes a plurality of upper recesses formed in the deck, each upper recess defined between an outer wall and a column. The disclosed example thermoformed tier sheet is specifically designed for the traditional plastic milk jugs, but could be modified for other types of containers.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings can be briefly described as follows:

FIG. 1 is a top perspective view of a tier sheet according to a first embodiment.

FIG. 2 is a bottom perspective view of the tier sheet of FIG. 1.

FIG. 3 shows a plurality of the empty tier sheets of FIG. 1 stacked.

FIG. 4 is a bottom perspective view of the tier sheet of FIG. 1 stacked on a jug.

FIG. 5 is another perspective view of the tier sheet and jug of FIG. 4.

FIG. 6 shows the tier sheet of FIG. 1 loaded with a plurality of jugs.

FIG. 7 is a bottom perspective view of the tier sheet and jugs of FIG. 6.

FIG. 8 shows the tier sheet and jugs of FIG. 6 with an identical tier sheet stacked thereon.

FIG. 9 shows the tier sheet and jugs of FIG. 6 adjacent three identical tier sheets.

FIG. 10 is an alternate view of the tier sheet and jugs of FIG. 9.

FIG. 11 shows the tier sheets and jugs of FIG. 9 on a pallet.

FIG. 12 shows a plurality of the tier sheets and jugs of FIG. 11 stacked in multiple layers on the pallet.

FIG. 13 is a perspective view of a tier sheet according to a second embodiment.

FIG. 14 is a bottom perspective view of the tier sheet of FIG. 13.

FIG. 15 is a top view of the tier sheet of FIG. 13.

FIG. 16 is a bottom view of the tier sheet of FIG. 13.

FIG. 17 is a side view of the tier sheet of FIG. 13.

FIG. 18 is an end view of the tier sheet of FIG. 13.

FIG. 19 shows the tier sheet of FIG. 13 with a jug stored thereon.

FIG. 20 shows a plurality of jugs on the tier sheet of FIG. 13.

FIG. 21 is a side view of the tier sheet and jugs of FIG. 20

FIG. 22 is an end view of the tier sheet and jugs of FIG. 20.

FIG. 23 is a top view of the tier sheet and jugs of FIG. 20.

FIG. 24 is an end view of the tier sheet of FIG. 13 stacked on a jug.

FIG. 25 is a bottom perspective view of the tier sheet and jug of FIG. 24.

FIG. 26 shows a plurality of tier sheets of FIG. 13 loaded with jugs and stacked on one another.

FIG. 27 is a bottom perspective view of the tier sheets and jugs of FIG. 26.

FIG. 28 is a section view through two of the layers of FIG. 26.

DETAILED DESCRIPTION

A tier sheet 10 according to a first embodiment is shown in FIG. 1. The tier sheet 10 includes a generally rectangular, generally planar deck 12 having a generally flat support surface with apertures therethrough for drainage and weight reduction. A lip 14 protrudes upward from the deck 12 along at least one of the perimeter edges of the deck 12.

FIG. 2 is a bottom perspective view of the tier sheet 10. A plurality of walls or ribs 16 protrude downward from the bottom surface of the deck 12. The ribs 16 define a plurality of generally rectangular (such as square) recesses 18. As shown, the recesses 18 may have rounded corners and may be arranged in an array, leaving diamond-shaped recesses at the intersection of every four recesses 18.

The embodiment of FIGS. 1-12 is injection molded as a single piece of plastic.

FIG. 3 shows a plurality of the tier sheets 10 stacked empty for efficient shipping and storage. The tier sheets 10 nest to the extent that the decks 12 can stack on one another with the lips 14 nesting somewhat. The lips 14 each include an upper rib offset outward from a lower rib, so that the upper rib of a lower tier sheet 10 can be received behind the lower rib of the upper tier sheet 10 (and below the upper rib of the upper tier sheet 10). This lets the ribs 16 on the bottom of the upper tier sheet 10 rest on the support surface of the lower tier sheet 10, and stacks the tier sheets 10 parallel to one another for a stable stack.

FIGS. 4 and 5 show the tier sheet 10 stacked on a beverage container 50, which in this example is a one gallon caseless plastic jug 50 have a body portion 52 with a generally rectangular (or square) cross section (with somewhat rounded corners). A cap 54 selectively closes an opening of the container 50. The upper wall of the container 50 also includes a raised portion 56 having a height the same as the cap 54. As shown in FIGS. 4 and 5, the upper portion of the container 50 fits snugly in any one of the recesses 18. The cap 54 abuts one of the ribs 16. The raised portion 56 of the container 50 abuts two ribs 16.

FIGS. 6 and 7 show a plurality of the containers 50 arranged on the tier sheet 10. The generally flat sides of the body portions 52 abut one another for compact and efficient use of space. The containers 50 are supported on the flat support surface of the deck 12 of the tier sheet 10. As shown in FIG. 7, one row of recesses 18 on the bottom of the tier sheet 10 is only a half, such that half of each container 50 in that row extends off the tier sheet 10.

As shown in FIG. 8, another tier sheet 10 is stacked on the array of containers 50. The upper portion of each container 50 is received in each of the recesses 18 (not visible in FIG. 8) in the manner of FIGS. 4 and 5. This provides increased stability in a stack of containers 50. Again, one row of containers 50 is only half covered by the tier sheet 10.

FIGS. 9 and 10 show four of the tier sheets 10 abutting one another to provide a continuous large support surface for containers 50. The tier sheets 10 are arranged so that the lips 14 of the tier sheets 10 are on opposite side edges of the combined surface. One row of containers 50 on each tier sheet 10 straddles two of the tier sheets 10.

As shown in FIG. 11, the four tier sheets 10 are sized to fit on a pallet 80. The pallet 80 includes a deck 82 supported by a plurality of columns 84. The four tier sheets 10 are each approximately the size of one quarter of the pallet deck 82 and thus may be considered quarter tier sheets 10. Alternatively full, ½ or ⅓ tier sheets could also be provided.

In FIG. 12, layers of containers 50 are stacked on the pallet 80 with a layers of tier sheets 10 between each layer of containers 50 to improve stability. The pallet 80, tier sheets 10 and containers 50 could be placed in a store in the configuration shown in FIG. 12 for sale to consumers. The consumers can select containers 50 from the tier sheets 10. The containers 50 can be easily slid across the deck 12 of the tier sheet to an outside edge. When one of the tier sheets 10 is empty, that tier sheet 10 can be removed easily to access the containers 50 below that tier sheet 10. In other words, it is not necessary for the consumers to remove all of the containers 50 in a single layer before accessing the next layer down. The interlocking of the upper portions of the containers 50 and the recesses 18 on the underside of the tier sheets 10 provides increased stability of the stack, even when one or more of the tier sheets 10 in a particular layer have been removed.

When empty, the tier sheets 10 can be stacked as shown in FIG. 3 and shipped back to the distribution facility with the pallet 80 to be reloaded with containers 50 and shipped back to the store.

FIGS. 13-28 illustrate another sheet 300 for stacking milk jugs 50. Referring to FIG. 13, the sheet 300 is single thermoformed plastic sheet. The sheet 300 generally includes a deck or bottom wall 302, side walls 304 and end walls 306. The side walls 304 and end walls 306 angle outward as they extend upward from the bottom wall 302, such that empty identical sheets 300 could be nested in one another. The bottom wall 302 includes a support surface 307 interrupted by a plurality of annular recesses 310 (or upper recesses) defining a plurality of cylindrical columns 312. Each annular recess 310 is defined between an outer cylindrical wall 311 and the cylindrical column 312. The uppermost surface of the cylindrical column 312 is coplanar with the support surface 307. A plurality of recessed channels 309 connect the annular recesses 310 to one another. The recessed channels 309 are less than half as deep as the annular recesses 310 but add reinforcement to the support surface 307. A plurality of diamond shaped recesses 308 are formed in the support surface 307 diagonally between the annular recesses 310. The diamond shaped recesses 308 are approximately the same depth as the recessed channels 309.

FIG. 14 is a bottom perspective view of the sheet 300. The outer cylindrical walls 311 project downward to a lowermost surface of the sheet 300. The bottom of each outer cylindrical wall 311 is connected to the bottom of one of the cylindrical columns 312 by a tapered annular wall 316 tapering upward and inward from the outer cylindrical wall 311 to the cylindrical column 312. The inner surface of the cylindrical column 312 defines a cylindrical recess.

FIG. 15 is a top view of the sheet 300. FIG. 16 is a bottom view of the sheet 300.

FIG. 17 is a side view of the sheet 300. The outer cylindrical walls 311 extend down below the side walls 304. The bottom edge of the side walls 304 includes recesses formed by the support surfaces 307.

FIG. 18 is an end view of the sheet 300. The outer cylindrical walls 311 extend down below the end walls 306. The bottom edge of the end walls 306 includes recesses formed by the support surfaces 307.

As shown in FIG. 19, a jug 50 (such as a milk jug 50) can fit securely adjacent an end wall 306 and a side wall 304 on the support surface 307 and on a cylindrical column 312. The jugs 50 include body portion tapering up to a neck having a cap. The sheet 300 can be filled with jugs 50 in this manner, as shown in FIG. 20. FIG. 21 is a side view of the sheet 300 and jugs of FIG. 20. FIG. 22 is an end view of the sheet 300 and jugs 50 of FIG. 20. FIG. 23 is a top view of the sheet 300 and jugs 50 of FIG. 20.

As shown in FIGS. 24 and 25, the neck and cap of each jug 50 can be received within the outer cylindrical wall 311 of a sheet 300 stacked thereon. This provides a stable stack of sheets 300 filled with jugs 50 as shown in FIGS. 26 and 27.

FIG. 28 is a section view through two layers of jugs 50 of FIG. 26. Each cap and neck of each jug 50 is received within the cylindrical column 312 of the sheet 300 stacked thereon. The tapered annular wall 316 distributes weight from the sheet 300 above to the body of the jug 50, so that not all the weight is on the cap of the jug 50. The layers of jugs 50 and tier sheets 300 may be stacked on a pallet, with four tier sheets 300 between each layer, as in the first embodiment. Again, the customer can remove one tier sheet 300 at a time to improve access to the jugs 50.

In this manner, jugs 50 can be shipped, stacked and stored in a stable stack. Consumers can remove jugs 50 from the stack. Empty sheets 300 can be nested within one another, returned and reused and eventually recycled.

In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. 

What is claimed is:
 1. A tier sheet comprising: a deck having a support surface; and a plurality of walls extending downward to define lower recesses for receiving the upper ends of containers therebelow.
 2. The tier sheet of claim 1 wherein the tier sheet is a single thermoformed sheet.
 3. The tier sheet of claim 2 further including a plurality of upper recesses formed in the deck, each upper recess defined between an outer wall and a column, wherein the plurality of walls includes the plurality of columns.
 4. The tier sheet of claim 3 wherein the upper recesses are annular and the plurality of columns are cylindrical.
 5. The tier sheet of claim 4 wherein the support surface is coplanar with uppermost surfaces of the plurality of columns.
 6. The tier sheet of claim 5 further including a plurality of recessed channels connecting the plurality of upper recesses to one another.
 7. The tier sheet of claim 6 wherein the recessed channels are shallower than the upper recesses.
 8. The tier sheet of claim 4 wherein the plurality of columns open downward to form the lower recesses.
 9. The tier sheet of claim 8 further including a plurality of outer cylindrical walls extending downward from the deck, each of the plurality of outer cylindrical walls spaced outward of one of the plurality of columns.
 10. The tier sheet of claim 9 further including a tapered annular wall connecting each outer cylindrical wall to the respective column.
 11. The tier sheet of claim 10 wherein the outer cylindrical walls extend downward from the deck further than the plurality of columns.
 12. The tier sheet of claim 11 further including a pair of opposed side walls extending upward from the deck and a pair of opposed end walls extending upward from the deck.
 13. The tier sheet of claim 1 wherein a plurality of columns open downward to form the lower recesses.
 14. The tier sheet of claim 13 further including a plurality of outer cylindrical walls extending downward from the deck, each of the plurality of outer cylindrical walls spaced outward of one of the plurality of columns and extending downward from the deck further than the plurality of columns.
 15. The tier sheet of claim 14 further including a tapered annular wall connecting each outer cylindrical wall to the respective column.
 16. The tier sheet of claim 15 in combination with a plurality of containers stacked therebelow, each container having a neck portion and a cap, the neck portion and cap of each container received in one of the plurality of columns.
 17. The combination of claim 16 wherein the plurality of containers are stacked in multiple layers with the tier sheet and a plurality of identical tier sheets between each layer.
 18. The tier sheet of claim 1 further including a lip protruding upward from an edge of the deck.
 19. The tier sheet of claim 18 wherein the plurality of walls define a plurality of generally rectangular recesses.
 20. The tier sheet of claim 19 wherein the generally rectangular recesses have rounded corners which form diamond-shaped recesses.
 21. The tier sheet of claim 20 further including a plurality of containers stacked therebelow, the containers each including a generally rectangular cross section, an upper wall of each container including a cap and a raised portion generally coplanar with the cap, the cap and raised portion of each container received in one of the plurality of generally rectangular 